Article of footwear having a sole structure including a fluid-filled chamber and an outsole, the sole structure, and methods for manufacturing

ABSTRACT

The disclosure is directed to an article of footwear including an upper and the sole structure, to the sole structure, and to a method for manufacturing the sole structure and a method for manufacturing the article of footwear. The sole structure includes a fluid-filled chamber and an outsole that at least partially surrounds the chamber.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No.14/641,789, filed Mar. 9, 2015, which is a Continuation in part of U.S.application Ser. No. 13/773,360, filed Feb. 21, 2013 (now U.S. Pat. No.9,420,848) the disclosures of which are hereby incorporated by referencein their entirety.

FIELD

The disclosure related to a sole structure for an article of footwear,to an article of footwear including the sole structure, and to a methodfor manufacturing the sole structure.

BACKGROUND

The present disclosure relates generally to an article of footwearhaving an upper and a sole structure including co-molded fluid-filledchamber and outsole. The disclosure also relates to the sole structure,to a method for manufacturing the sole structure, and to a method formanufacturing the article of footwear having the sole structure.

Conventional articles of athletic footwear include two primary elements,an upper and a sole structure. The upper is generally formed from aplurality of elements (e.g., textiles, foam, leather, synthetic leather)that are stitched or adhesively bonded together to form an interior voidfor securely and comfortably receiving a foot. The sole structureincorporates multiple layers that are conventionally referred to as asock liner, a midsole, and an outsole. The sock liner is a thin,compressible member located within the void of the upper and adjacent toa plantar (i.e., lower) surface of the foot to enhance comfort. Themidsole is secured to the upper and forms a middle layer of the solestructure that attenuates ground reaction forces (i.e., impartscushioning) during walking, running, or other ambulatory activities. Theoutsole forms a ground-contacting element of the footwear and is usuallyfashioned from a durable and wear-resistant rubber material thatincludes texturing to impart traction.

The primary material forming many conventional midsoles is a polymerfoam, such as polyurethane or ethylvinylacetate. In some articles offootwear, the midsole may also incorporate a fluid-filled chamber thatincreases durability of the footwear and enhances ground reaction forceattenuation of the sole structure. In some footwear configurations, thefluid-filled chamber may be at least partially encapsulated within thepolymer foam, as in U.S. Pat. No. 5,755,001 to Potter, et al., U.S. Pat.No. 6,837,951 to Rapaport, and U.S. Pat. No. 7,132,032 to Tawney, et al.In other footwear configurations, the fluid-filled chamber maysubstantially replace the polymer foam, as in U.S. Pat. No. 7,086,132 toDojan, et al. In general, the fluid-filled chambers are formed from apolymer material that is sealed and pressurized, but may also besubstantially unpressurized or pressurized by an external source. Insome configurations, textile or foam tensile members may be locatedwithin the chamber, or reinforcing structures may be bonded to anexterior surface of the chamber to impart shape to or retain an intendedshape of the chamber.

Fluid-filled chambers suitable for footwear applications may bemanufactured through various processes, including a two-film technique,thermoforming, and blow molding. In the two-film technique, two planarsheets of polymer material are bonded together in various locations toform the chamber. In order to pressurize the chamber, a nozzle or needleconnected to a fluid pressure source is inserted into a fill inletformed in the chamber. Following pressurization, the fill inlet issealed and the nozzle is removed. Thermoforming is similar to thetwo-film technique, but utilizes a heated mold that forms or otherwiseshapes the sheets of polymer material during the manufacturing process.In blow-molding, a molten or otherwise softened elastomeric material inthe shape of a tube (i.e., a parison) is placed in a mold having thedesired overall shape and configuration of the chamber. The mold has anopening at one location through which pressurized air is provided. Thepressurized air induces the liquefied elastomeric material to conform tothe shape of the inner surfaces of the mold, thereby forming thechamber, which may then be pressurized.

Manufacture of articles of footwear typically involves ensuring thatrelated parts are in correct location relative to each other.Manufacture of articles of footwear also may involve ensuring that partsdo not move when placed during assembly, for example, while adhesivecures and sets. Also, consumers demand products that are attractive,well-constructed, and provide selected properties and characteristics.

Therefore, there exists a need in the art for an article of footwearthat provides properties and characteristics sought by a customer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a lateral side elevational view of an embodiment of an articleof footwear;

FIG. 2 is a bottom view of the article of footwear;

FIG. 3 is a cross-sectional view of the article of footwear of FIG. 2;

FIG. 4 is a bottom view of a forefoot sole structure of an article offootwear;

FIG. 5 is a cross-sectional view of an article of footwear having aforefoot sole structure of FIG. 4;

FIG. 6 is a bottom perspective view of a forefoot outsole of FIG. 2;

FIG. 7 is an exploded view illustrating a relationship between aforefoot outsole and a forefoot component that form a forefoot solestructure of FIG. 2;

FIG. 8 is an exploded view illustrating a relationship between a heeloutsole and a heel component that form a heel sole structure of FIG. 2;

FIG. 9 is an exploded view illustrating a relationship between aforefoot outsole and a forefoot component that form a forefoot solestructure of FIG. 4;

FIG. 10 is a cross-sectional view of an open mold illustrating arelationship of the parts for forming a forefoot sole structure of FIG.4 in the mold;

FIG. 11 is a cross-sectional view of a closed mold illustrating aforefoot sole structure of FIG. 4 formed in the mold;

FIG. 12 is a cross-sectional view of an open mold illustrating therelationship of the parts for forming a heel sole structure of FIG. 2 inthe mold;

FIG. 13 is a cross-sectional view of a partially-formed heel solestructure of FIG. 2 in a partially-open mold;

FIG. 14 is a cross-sectional view of a closed mold illustrating the heelsole structure of FIG. 2 formed in the mold;

FIG. 15 is a cross-sectional view of a heel sole structure of FIG. 2removed from the mold opened after forming the structure;

FIG. 16 is a top view of the interior of a forefoot outsole of FIG. 4;

FIG. 17 is a cross-sectional view of an embodiment of a heel solestructure;

FIG. 18 is a cross-sectional view of another embodiment of a heel solestructure;

FIG. 19 is a cross-sectional view of still another embodiment of a heelsole structure;

FIG. 20 is a bottom view of an embodiment of an article of footwear;

FIG. 21 is a bottom view of an embodiment of a heel outsole;

FIG. 22 is a bottom view of an embodiment of a heel outsole showinginternal structure.

FIG. 23 is a bottom view of another embodiment of a heel outsole;

FIG. 24 is an enlarged view of a portion of FIG. 23;

FIG. 25 is a cross-sectional view of a portion of FIG. 24; and

FIG. 26 is a cross-sectional view of a portion of a heel outsole adheredto a heel component.

DETAILED DESCRIPTION

The disclosure provides an article of footwear that provides propertiesand characteristics sought by a customer. Embodiments of the disclosureprovide a sole structure for an article of footwear comprising afluid-filled chamber co-molded with an outsole that at least partiallysurrounds the chamber. Embodiments of the disclosure also provide anarticle of footwear including an upper and the sole structure.Embodiments of the disclosure provide a method for manufacturing thesole structure. The disclosure also is directed to a method formanufacturing the article of footwear.

In one aspect, the disclosure relates to a sole structure for article offootwear. The sole structure includes a fluid-filled chamber and anoutsole. The fluid-filled chamber has an edge, an upper surface, and alower surface. The outsole is co-molded to at least a part of the lowersurface of the fluid-filled chamber and at least part of the edge of thefluid-filled chamber. The outsole is co-extensive with at least part ofthe lower surface of the fluid-filled chamber and with at least part ofthe edge of the fluid-filled chamber.

In another aspect, the disclosure relates to an article of footwearhaving an upper and a sole structure. The sole structure includes afluid-filled chamber and an outsole. The fluid-filled chamber has anedge, an upper surface, and a lower surface. The outsole is co-molded toat least a part of the lower surface of the fluid-filled chamber and toat least a part of the edge of the fluid-filled chamber. The outsole isco-extensive with at least part of the lower surface of the fluid-filledchamber and with at least part of the edge of the fluid-filled chamber.At least part of the upper is secured to at least part of the solestructure.

An aspect of the disclosure relates to a method for manufacturing thesole structure comprising a fluid-filled chamber and an outsole. Thefluid-filled chamber has an edge, an upper surface, and a lower surface.In accordance with the method, the outsole is located in position in thesecond portion of a mold having a first mold portion and a second moldportion to contact at least a part of the edge of the chamber and atleast a part of the lower surface of the chamber. A fluid-filled chamberprecursor is placed in the mold, and the first mold portion and thesecond mold portion are closed. The upper surface of the fluid-filledchamber is conformed to the shape of the first mold portion, the lowersurface of the fluid-filled chamber is conformed to the shape of thesecond mold portion with the outsole therein, and the edge of thefluid-filled chamber precursor is conformed to the shape of the moldwith the outsole therein by a technique selected from the groupconsisting of drawing a vacuum in the mold, introducing pressure intothe fluid-filled chamber precursor, and blends thereof, to form thefluid-filled chamber with the outsole co-molded therewith.

In another aspect, the disclosure relates to a method for minimizingdeleterious effects of incomplete bonding caused by gas-relatedinclusions in the bond between the bonding surface of a fluid-filledchamber and the bonding surface of an outsole. At least one of thebonding surfaces includes a texture having lands and grooves to ensure abond between the lands and the other surface. The grooves are deeperthan the thickness of an adhesive or of a partly molten opposingsurface.

In some embodiments, at least part of the upper is secured to at leastpart of the sole structure.

In some embodiments, at least part of the ground-engaging surface of theoutsole is textured.

In some embodiments, the edge of the fluid-filled chamber is flush withthe outsole.

In some embodiments, wherein the outsole is adhered to the fluid-filledchamber by partial melting of at least one of the chamber-engagingsurface of the outsole, the lower surface of the fluid-filled chamber,and the edge of the fluid-filled chamber.

In some embodiments, the outsole is adhered to the fluid-filled chamberby a layer of adhesive having a thickness.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth,wherein the thickness of the adhesive is less than the depth of the lowareas.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth, andthe outsole further having gas escape openings.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth, andthe outsole further having gas escape openings in fluid communicationwith gas accumulation areas and passages.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth, andthe outsole further having gas escape openings in fluid communicationwith the low areas.

In other aspects, the disclosure is directed to a method ofmanufacturing a sole structure for an article of footwear comprising anupper and a sole structure. In accordance with the method, a componentincluding a fluid-filled chamber having an edge, an upper surface, and alower surface, is provided. An outsole is co-molded to at least a partof the lower surface of the fluid-filled chamber and to at least a partof the edge of the fluid-filled chamber. The outsole is at leastpartially co-extensive with the lower surface of the chamber and with atleast a part of the edge of the chamber, and the outsole has achamber-engaging surface and a ground-engaging surface.

In some embodiments, the method further comprises locating the outsolein the second portion of a mold having a first mold portion and a secondmold portion in position to contact at least a part of the edge of thechamber and at least a part of the lower surface of the chamber. Afluid-filled chamber precursor is placed in the mold, and the first moldportion and the second mold portion are closed.

The upper surface of the fluid-filled chamber is conformed to the shapeof the first mold portion, the lower surface of the fluid-filled chamberis conformed to the shape of the second mold portion with the outsoletherein, and the edge of the fluid-filled chamber precursor is conformedto the shape of the mold with the outsole therein using a techniqueselected from the group consisting of drawing a vacuum in the mold,introducing pressure into the fluid-filled chamber precursor, and blendsthereof, to form the fluid-filled chamber with the outsole co-moldedtherewith.

In some embodiments, at least part of the upper is connected to at leastpart of the sole structure.

In some embodiments, adhesive is applied to the chamber-engaging surfaceof the outsole before placing the fluid-filled chamber precursor intothe mold.

In some embodiments, the adhesive is dried before placing thefluid-filled chamber precursor in the mold.

In some embodiments, the method further comprises co-extruding theoutsole with the lower surface of the fluid-filled chamber precursor.

In some embodiments, the method further comprises partially melting atleast one of the lower surface of the fluid-filled chamber, the edge ofthe fluid-filled chamber, and the chamber-engaging surface of theoutsole.

In some embodiments, the method further comprises forming a texture onthe chamber-engaging surface, the texture having high areas and lowareas, and forming gas escape openings in the outsole.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth, andthe outsole further has gas escape openings in fluid communication withgas accumulation areas and passages.

In some embodiments, the chamber-engaging surface of the outsole istextured, the texture having high areas and low areas having depth, andthe outsole further has gas escape openings in fluid communication withthe low areas.

In some embodiments, the edge of the fluid-filled chamber is conformedto the edge of the mold by introducing pressure into the fluid-filledchamber precursor.

In another aspect, the disclosure relates to a method for manufacturingan article of footwear having an upper and a sole structure. Inaccordance with the disclosure, the method comprises securing at leastpart of the upper to at least part of the sole structure. The solestructure comprises a fluid-filled chamber having an edge, an uppersurface, and a lower surface. The outsole is co-molded to at least apart of the lower surface of the fluid-filled chamber and to at least apart of the edge of the fluid-filled chamber. The outsole isco-extensive with at least part of the lower surface of the fluid-filledchamber and with at least part of the edge of the fluid-filled chamber.

Other systems, methods, features, and advantages of the invention willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the invention, and be protected by the followingclaims.

The disclosure provides an article of footwear that provides propertiesand characteristics sought by a customer. Embodiments of the disclosureprovide a sole structure for an article of footwear comprising afluid-filled chamber co-molded with an outsole that at least partiallysurrounds the chamber. Embodiments of the disclosure also provide anarticle of footwear including an upper and the sole structure.Embodiments of the disclosure provide a method for manufacturing thesole structure. The disclosure also is directed to a method formanufacturing the article of footwear.

The following discussion and accompanying figures disclose variousfluid-filled chambers. Concepts related to the chambers are disclosedwith reference to footwear that is suitable for running. The chambersare not limited to footwear designed for running, however, and may beutilized with a wide range of athletic footwear styles, includingbasketball shoes, cross-training shoes, cycling shoes, football shoes,soccer shoes, tennis shoes, and walking shoes, for example. Variousconfigurations of the chambers may be utilized with footwear styles thatare generally considered to be non-athletic, including dress shoes,loafers, sandals, and boots. Accordingly, concepts related to thechambers may apply to a wide variety of footwear styles.

General Footwear Structure

An article of footwear 100 is depicted in FIG. 1 and FIG. 2 as includingan upper 120 and a sole structure 130. Upper 120 provides a comfortableand secure covering for a foot of a wearer. As such, the foot may belocated within upper 120 to effectively secure the foot within articleof footwear 100 or otherwise unite the foot and article of footwear 100.Sole structure 130 is secured to a lower area of upper 120 and extendsbetween the foot and the ground to attenuate ground reaction forces(i.e., cushion the foot), provide traction, enhance stability, andinfluence the motions of the foot, for example. In effect, solestructure 130 is located under the foot and supports the foot.

For reference purposes, footwear 100 may be divided into three generalregions: a forefoot region 111, a midfoot region 112, and a heel region113. Forefoot region 111 generally includes portions of article offootwear 100 corresponding with toes of the foot and the jointsconnecting the metatarsals with the phalanges. Midfoot region 112generally includes portions of footwear 100 corresponding with an archarea of the foot. Heel region 113 generally corresponds with rearportions of the foot, including the calcaneus bone. Article of footwear100 also includes a lateral side 114 and a medial side 115, whichcorrespond with opposite sides of article of footwear 100 and extendthrough each of forefoot region 111, midfoot region 112, and heel region113. More particularly, lateral side 114 corresponds with an outsidearea of the foot (i.e. the surface that faces away from the other foot),and medial side 115 corresponds with an inside area of the foot (i.e.,the surface that faces toward the other foot). Forefoot regions 111,midfoot region 112, heel region 113, lateral side 114, and medial side115 are not intended to demarcate precise areas of footwear 100. Rather,forefoot region 111, midfoot region 112, heel region 113, lateral side114, and medial side 115 are intended to represent general areas offootwear 100 to aid in the following discussion. The characterizationsof forefoot region 111, midfoot region 112, heel region 113, lateralside 114, and medial side 115 may be applied to article of footwear 100,and also may be applied to upper 120, sole structure 130, forefootstructure 131, heel structure 132, and individual elements thereof.

Upper 120 is depicted as having a substantially conventionalconfiguration. A majority of upper 120 incorporates various materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to form an interior void forsecurely and comfortably receiving a foot. The material elements may beselected and located in upper 120 to selectively impart properties ofdurability, air-permeability, wear-resistance, flexibility, and comfort,for example. The void in upper 120 is shaped to accommodate the foot.When the foot is located within the void, therefore, upper 120 extendsalong a lateral side of the foot, along a medial side of the foot, overthe foot, around the heel, and under the foot. An ankle opening 121 inheel region 113 provides the foot with access to the void. A lace 122extends over a tongue 123 and through various lace apertures 124 orother lace-receiving elements in upper 120. Lace 122 and theadjustability provided by tongue 123 may be utilized in a conventionalmanner to modify the dimensions of ankle opening 121 and the interiorvoid, thereby securing the foot within the interior void andfacilitating entry and removal of the foot from the interior void.

Further configurations of upper 120 may also include one or more of (a)a toe guard positioned in forefoot region 111 and formed of awear-resistant material, (b) a heel counter located in heel region 113for enhancing stability, and (c) logos, trademarks, and placards withcare instructions and material information. Given that various aspectsof the present discussion primarily relate to sole structure 130, upper120 may exhibit the general configuration discussed above or the generalconfiguration of practically any other conventional or non-conventionalupper. Accordingly, the structure of upper 120 may vary significantlywithin the scope of the present disclosure.

Sole Structure

The primary elements of sole structure 130 are a forefoot sole structure131 including a forefoot component 140 and a forefoot outsole 160, and aheel sole structure including a heel component 150 and a heel outsole170. In some embodiments, each of forefoot component 140 and heelcomponent 150 may be directly secured to a lower area of upper 120.Forefoot component 140 and heel component 150 are formed from a polymermaterial that encloses a fluid, which may be a gas, liquid, or gel.During walking and running, for example, forefoot component 140 and heelcomponent 150 may compress between the foot and the ground, therebyattenuating ground reaction forces. That is, forefoot component 140 andheel component 150 are inflated and generally pressurized with the fluidto cushion the foot.

In some configurations, sole structure 130 may include a foam layer, forexample, that extends between upper 120 and one or both of forefootcomponent 140 and heel component 150, or a foam element may be locatedwithin indentations in the lower areas of forefoot component 140 andheel component 150. In other configurations, forefoot sole structure 131may incorporate plates, moderators, lasting elements, or motion controlmembers that further attenuate forces, enhance stability, or influencethe motions of the foot. Heel sole structure 132 also may include suchmembers to further attenuate forces, enhance stability, or influence themotions of the foot.

In addition to providing a wear surface in article of footwear 100,forefoot outsole 160 and heel outsole 170 may enhance various propertiesand characteristics of sole structure 130. Properties andcharacteristics of the outsoles, such as the thickness, flexibility, theproperties and characteristics of the material used to make the outsole,and stretch, may be varied or selected to modify or otherwise tune thecushioning response, compressibility, flexibility, and other propertiesand characteristics of sole structure 130. Reinforcement of the outsole(for example, inclusion of structural elements, such as ribs),apertures, the height of the overlap, the number and location of theedges that overlap, or other features of an outsole all may be used totune the responses of the sole structure. An outsole also mayincorporate tread elements, such as protrusions, ridges, orground-engaging lugs or sections, that impart traction. In someembodiments, an outsole may be replaced by a plate or other structuralelement. A plate may have features that assist with securing an outsoleor other element to heel component 150.

In particular, overlap of a portion of an outsole away from theground-engaging portion and up the edge of a forefoot component or aheel component may be used to tune the elastic response and cushioningresponse of the resultant sole structure. With the guidance providedherein, these and other properties and characteristics of the outsolemay be considered by the user in combination with the properties andcharacteristics of the fluid-filled components of the components toadjust the responses of a sole structure.

Sole structure 130 may be translucent or transparent, and may be coloredor patterned for aesthetic appeal.

Forefoot outsole 160 is secured to lower areas of forefoot component140. In some embodiments, forefoot sole structure 131 may extend intomidfoot region 112. The forefoot outsole 160 also may be secured tolower areas of forefoot component 140 in midfoot region 112. Heeloutsole 170 is secured to lower areas of heel component 150. Both heelcomponent 150 and heel outsole 170 may extend into midfoot region 112.Forefoot outsole 160 and heel outsole 170 may be formed from awear-resistant material. The wear-resistant material may be transparentor translucent to provide a visually appealing effect. Thewear-resistant material may be textured on the ground-engaging portionsto impart traction. In some embodiments, the wear-resistant material mayhave ground-engaging lugs or portions 135, as illustrated in FIG. 1 andFIG. 2.

FIG. 3 illustrates a cross-sectional view of article of footwear 100 atsection line 3-3 with forefoot sole structure 131, including forefootcomponent 140 and forefoot outsole 160 with ground-engaging lugs 135. Asdepicted in FIG. 3, upper 120 also includes a sock-liner 125 that islocated within the void and positioned to extend under a lower surfaceof the foot to enhance the comfort of article of footwear 100.

FIG. 4 illustrates a bottom view of another embodiment of forefoot solestructure 1131 including forefoot component 1140 and forefoot outsole1160 with ground-engaging lugs 1135 associated therewith. Forefootcomponent 1140 is directly secured to a lower area of upper 120 and isformed from a polymer material that encloses a fluid, which may be agas, liquid, or gel. Forefoot component 1140 may extend into midfootregion 112. Forefoot component 1140 may compress between the foot andthe ground, thereby attenuating ground reaction forces. Fluid-filledchambers 1145 of forefoot component 1140 may be inflated and generallypressurized with a fluid to cushion the foot.

Forefoot outsole 1160, which also may extend into midfoot region 112, issecured to lower areas of forefoot component 1140. Forefoot outsole 1160may include individual portions that cover individual lower areas offluid-filled chambers 1145 of forefoot component 1140. Forefoot outsole1160 may be formed from wear-resistant material and, in comeembodiments, may include ground-engaging portions or lugs 1135. Forefootoutsole 1160 may be transparent or translucent, and, in someembodiments, may be textured to improve traction.

FIG. 5 illustrates a cross-sectional view of an article of footwear 100at section line 3-3 for another embodiment of forefoot sole structure1130 including forefoot component 1140 and forefoot outsole 1160. Upper120 includes laces 122, tongue 123, and sock-liner 125.

Forefoot component 140 and heel component 150 are formed from a polymermaterial that defines an upper surface, a lower surface, and an edge.Forefoot component 140 may include a plurality of forefoot componentfluid-filled chambers 145 and heel component 150 may include a pluralityof fluid-filled chambers 155, each of which may be in fluidcommunication with at least one other chamber of the component. Uppersurface 141 of forefoot component 140 is facing downward so that theforefoot component lower surface 142 and forefoot component edge 143 ofeach forefoot component fluid-filled chamber 145 are clearly visible inFIG. 7. Similarly, upper surface 1141 of forefoot component 1140 isfacing downward so that the forefoot component lower surface 1142 andforefoot component edge 1143 of each forefoot component fluid-filledchamber 1145 are clearly visible in FIG. 9. Heel component fluid-filledchamber 155, heel component upper surface 151, heel component lowersurface 152, and heel component edge 153 of heel component 150 areillustrated in FIG. 8.

FIG. 6 illustrates an exemplary bottom surface of forefoot outsole 160.Forefoot outsole 160 includes forefoot outsole compartments 165 havingground-engaging lugs 135 on forefoot outsole outer lower surface 162.Forefoot outsole compartments 165 also include forefoot outsole outsideedge 163.

A relationship between an embodiment of a forefoot component 140 and anembodiment of a forefoot outsole 160 is depicted in FIG. 7. Similarly,FIG. 8 is an illustration of the relationship between an embodiment ofheel component 150 and an embodiment of heel outsole 170.

The relationship between an embodiment of forefoot component 140 and anembodiment of forefoot outsole 160 is illustrated in FIG. 7. In thisembodiment, each forefoot component fluid-filled chamber 145 correspondswith a similarly-sized, congruently-shaped forefoot outsole compartment165. In this embodiment, each forefoot outsole compartment 165 isaligned with and sufficiently large to accommodate a similarly-sized,congruently-shaped forefoot component fluid-filled chamber 145. In someembodiments, a forefoot component fluid-filled chamber 145 may combinewith a forefoot outsole compartment 165 in a snug relationship. Forefootoutsole 160 then may be associated with forefoot component 140 byinserting forefoot component fluid-filled chambers 145 into thecorresponding forefoot outsole compartments 165. In some embodiments, aforefoot outsole compartment 165 is bonded to a forefoot componentfluid-filled chamber 145. In some embodiments, forefoot component 140 isco-molded with forefoot outsole 160. In some embodiments, forefootoutsole 160 is co-extensive with or overlaps at least a part of forefootcomponent lower surface 142 or of inside surface 164 (see FIG. 16), andforefoot component edge 1143 is co-extensive with or overlaps at least apart of forefoot component lower surface 1142 or sole inside surface1164. In some embodiments, forefoot outsole compartments 165 surroundforefoot component fluid-filled chambers 145.

FIG. 8 depicts relationship between an embodiment of heel component 150and an embodiment of heel outsole 170. In this embodiment, a heelcomponent fluid-filled chamber 155 corresponds with a heel outsolecompartment 175. In the embodiment illustrated in FIG. 8, the singleheel outsole compartment 175 may be associated with a similarly-sized,congruently-shaped heel component fluid-filled chamber 155. In anotherembodiment, heel component 150 may comprise plural fluid-filled chambers155 and heel outsole 170 may comprise plural heel outsole compartments175. In these embodiments, each heel outsole 170 fits ontosimilarly-sized, congruently-shaped heel component 150 by ensuring thateach heel outsole compartment 175 is aligned with and sufficiently largeenough to accommodate each heel component fluid-filled chamber 155. Insome embodiments, a heel component fluid-filled chamber 155 may combinewith a heel outsole compartment 175 in a snug relationship. Heel outsole170 then may be associated with heel component 150 by inserting heelcomponent fluid-filled chambers 155 into the corresponding heel outsolecompartments 175. In some embodiments, a heel outsole compartment 175 isbonded to a heel component fluid-filled chamber 155. In someembodiments, heel component 150 is co-molded with heel outsole 170. Insome embodiments, heel outsole compartment 175 surrounds heel componentfluid-filled chamber 155. In some embodiments, the heel outsole 170 isco-extensive with or at least partly overlaps at least a part of heelcomponent edge 153.

FIG. 9 illustrates a relationship between forefoot component 1140 andforefoot outsole 1160 in forefoot sole structure 1131. Each of forefootcomponent fluid-filled chambers 1145 has a section or compartment 1165of forefoot outsole 1160 associated therewith. Each forefoot outsolesection 1165 of forefoot outsole 1160 may wrap around the corner betweenforefoot component fluid-filled chamber lower surface 1142 and forefootcomponent fluid-filled chamber edge 1143 of each forefoot componentfluid-filled chamber 1145 of forefoot component 1140. Lugs 1135 may beattached to or formed on the lower surface of forefoot outsole 1160.

FIG. 9 illustrates another embodiment of a forefoot sole structure.Forefoot sole structure 1131 includes forefoot component 1140 havingforefoot component fluid-filled chambers 1145 formed from a polymermaterial that defines forefoot component upper surface 1141, forefootcomponent lower surface 1142, and forefoot component edge 1143. Forefootcomponent upper surface 1141 is facing downward in FIG. 9.

FIG. 9 also illustrates the relationship between an embodiment offorefoot outsole 1160 and forefoot component 1140. As illustrated inFIG. 9, forefoot outsole 1160 includes forefoot outsole outer lowersurface 1162 having ground-engaging lugs 1135 thereon. Forefoot outsole1160 further includes forefoot outsole compartment edges 1163 thatextend over at least part of forefoot component edge 1143.

Method for Manufacture

An outsole may be attached to a corresponding component in any suitablemanner. In some embodiments, the outsole and component are adhered byadhesion as part of a co-molding process. In some embodiments, theoutsole and corresponding component are adhered by partial melting aspart of a co-molding process.

Forefoot component 140 and heel component 150 may be formed from anysuitable polymeric material. Forefoot component 140 and heel component150 may be formed of a single layer of material or multiple layers, andmay be thermoformed or otherwise shaped. Examples of polymeric materialsthat may be utilized for forefoot component or a heel component includeany of polyurethane, urethane, polyester, polyester polyurethane,polyether, polyether polyurethane, latex, polycaprolactone,polyoxypropylene, polycarbonate macroglycol, and blends thereof. Theseand other polymeric materials, and an exemplary embodiment of forefootcomponent 140 and heel component 150, and of a method for manufacturingthem, may be found in co-pending application Ser. No. 13/773,360, filedFeb. 21, 2013, by Campos II et al., and entitled ARTICLE OF FOOTWEARINCORPORATING A CHAMBER SYSTEM AND METHODS FOR MANUFACTURING THE CHAMBERSYSTEM, the entirety of which is hereby incorporated by reference.

In a co-molding process, an outsole first may be formed in any suitablemanner. An outsole typically may be formed from any durable material.Typically, outsole material is tough, durable, resistant to abrasion andwear, flexible, and skid-resistant. In some embodiments, polyurethanematerials sufficiently durable for ground contact. Suitablethermoplastic polyurethane elastomer materials include Bayer Texin®285,available from Bayer. Elastollan® SP9339, Elastollan® SP9324, andElastollan® C70S, available from BASF, also are suitable. Polyurethaneand other polymers that may not be sufficiently durable for directground contact may be used to form part of an outsole in someembodiments. In such embodiments, a rubber outsole may be adhered orcemented onto the outsole. In embodiments, the outsole material istransparent or translucent. In embodiments, ground-engaging lugs may beintegrally formed as part of an outsole, or may be separately formed andadhered to the outsole. The outsole may have a textured ground-engagingsurface to improve traction.

An outsole then is placed in a mold that accommodates the outsole in anappropriate relationship with the corresponding component to beco-molded therewith. In some embodiments, adhesive may be applied to theappropriate surfaces of the outsole, the component, or both. Thecomponent then may be co-molded with the corresponding outsole to form aforefoot sole structure or a heel sole structure.

FIG. 10 and FIG. 11 depict a mold for co-molding forefoot component 1140with forefoot outsole 1160 with ground-engaging lugs 1135 thereon toform forefoot sole structure 1131. In some embodiments, forefoot outsole1160 wraps at least a portion of forefoot component edge 1143 onforefoot component fluid-filled chamber 1145. This forefoot outsolesection 1165 of forefoot outsole compartment edge 1163 that wraps atleast a portion of forefoot component edge 1143 may be used to tune thecushioning response of the forefoot sole structure 1131, as describedherein. The wrapping portion of forefoot outsole compartment edge 1163may provide additional strength and resistance to flexure at thesidewall or edge of forefoot component fluid-filled chamber 1145. Insome embodiments, forefoot outsole compartment edge 1163 wraps a shortdistance up fluid-filled chamber edge 1143. In other embodiments,forefoot outsole compartment edge 1163 wraps further up fluid-filledchamber edge 1143 to provide additional stiffness and better protectfluid-filled chamber edge 1143 from damage or wear. Forefoot solestructure 1131 is an embodiment of a forefoot sole structure havingforefoot outsole 1160 wrapping a significant portion of forefootcomponent fluid-filled chamber 1145.

FIG. 10 and FIG. 11 are cross-sectional depictions of mold 1700 forforefoot component 1140. As shown in FIG. 10 and FIG. 11, forefootcomponent 1140 is co-molded with forefoot outsole 1160 present in themold. Adhesive also may be present on appropriate portions of forefootcomponent 1140, particularly forefoot component fluid-filled chamberedges 1143 and forefoot component fluid-filled chamber lower surface1142, or to chamber-engaging surfaces of forefoot outsole 1160 that willbe in contact with forefoot component 1140.

A variety of manufacturing processes may be utilized to form forefootsole structure 1131. In some embodiments, mold 1700 that may be utilizedin the manufacturing process is depicted as including a first moldportion 1710 and a second mold portion 1720. Mold 1700 is utilized toform forefoot component 1140 from a first polymer layer 1810 and asecond polymer layer 1820, which are the polymer layers forming forefootcomponent upper surface 1141 and forefoot component lower surface 1142,respectively. More particularly, mold 1700 facilitates the manufacturingprocess by (a) shaping first polymer layer 1810 and second polymer layer1820 in areas corresponding with forefoot component fluid-filledchambers 1145, forefoot component flange 1146, and conduits betweenchambers, and (b) joining first polymer layer 1810 and second polymerlayer 1820 in areas corresponding with forefoot component flange 1146and forefoot component web area 1147.

Various surfaces or other areas of mold 1700 will now be defined for usein discussion of the manufacturing process. Referring now to FIG. 10 andFIG. 11, first mold portion 1710 includes a pinch surface 1730, a firstseam-forming surface 1740, and a compression surface 1750. Pinchsurfaces 1730 and first seam-forming surface 1740 are angled relative toeach other, with pinch surface 1730 being more vertical than firstseam-forming surface 1740. Second mold portion 1720 includes a pinchedge 1760 and a second seam-forming surface 1770. Whereas pinch edge1760 is a relatively sharp corner or angled area in second mold portion1720, second seam-forming surface 1770 extends downward and isgenerally, although not necessarily, parallel to pinch surface 1730. Avoid volume 1790 within mold 1700 and between mold portions 1710 and1720 has a shape of forefoot component 1140, prior to pressurization,and forms various features of forefoot component 1140. A portion of thisvoid volume 1790 is identified as a depression 1780 in second moldportion 1720.

Each of first polymer layer 1810 and second polymer layer 1820 areinitially located between each of first mold portion 1710 and secondmold portion 1720, which are in a spaced or open configuration, asdepicted in FIG. 10 and FIG. 11. In this position, first polymer layer1810 is positioned adjacent or closer to first mold portion 1710, andsecond polymer layer 1820 is positioned adjacent or closer to secondmold portion 1720. A shuttle frame or other device may be utilized toproperly position first polymer layer 1810 and second polymer layer1820. As part of the manufacturing process, one or both of first polymerlayer 1810 and second polymer layer 1820 are heated to a temperaturethat facilitates shaping and bonding. As an example, various radiantheaters or other devices may be utilized to heat first polymer layer1810 and second polymer layer 1820, possibly prior to being locatedbetween first mold portion 1710 and second mold portion 1720. As anotherexample, mold 1700 may be heated such that contact between mold 1700 andfirst polymer layer 1810 and second polymer layer 1820 at a laterportion of the manufacturing process raises the temperature to a levelthat facilitates shaping and bonding.

Once first polymer layer 1810 and second polymer layer 1820 are properlypositioned, first mold portion 1710 and second mold portion 1720translate or otherwise move toward each other and begin to close uponfirst polymer layer 1810 and second polymer layer 1820. As first moldportion 1710 and second mold portion 1720 move toward each other,various techniques may be utilized to draw first polymer layer 1810 andsecond polymer layer 1820 against surfaces of first mold portion 1710and second mold portion 1720, thereby beginning the process of shapingfirst polymer layer 1810 and second polymer layer 1820. For example, airmay be partially evacuated from the areas between (a) first mold portion1710 and first polymer layer 1810 and (b) second mold portion 1720 andsecond polymer layer 1820. More particularly, air may be withdrawnthrough various vacuum ports in first mold portion 1710 and second moldportion 1720. By removing air, first polymer layer 1810 is drawn intocontact with the surfaces of first mold portion 1710 and second polymerlayer 1820 is drawn into contact with the surfaces of second moldportion 1720. As another example, air may be injected into the areabetween first polymer layer 1810 and second polymer layer 1820, therebyelevating the pressure between first polymer layer 1810 and secondpolymer layer 1820. During a preparatory stage of this process, aninjection needle may be located between first polymer layer 1810 andsecond polymer layer 1820, and a gas, liquid, or gel, for example, thenmay be ejected from the injection needle such that first polymer layer1810 and second polymer layer 1820 engage the surfaces of mold 1700.Each of these techniques may be used together or independently.

As first mold portion 1710 and second mold portion 1720 continue to movetoward each other, first polymer layer 1810 and second polymer layer1820 are pinched between first mold portion 1710 and second mold portion1720. More particularly, first polymer layer 1810 and second polymerlayer 1820 are compressed between pinch surface 1730 and pinch edge1760. In addition to beginning the process of separating excess portionsof first polymer layer 1810 and second polymer layer 1820 from portionsthat form forefoot component 1140, the pinching of first polymer layer1810 and second polymer layer 1820 begins the process of bonding orjoining first polymer layer 1810 and second polymer layer 1820 in thearea of forefoot component flange 1146.

Following the pinching of first polymer layer 1810 and second polymerlayer 1820, first mold portion 1710 and second mold portion 1720 proceedwith moving toward each other and into a closed configuration, asdepicted in FIG. 11. As the mold closes, pinch surface 1730 contacts andslides against a portion of second seam-forming surface 1770. Thecontact between pinch surface 1730 and second seam-forming surface 1770effectively severs excess portions of first polymer layer 1810 andsecond polymer layer 1820 from portions that form forefoot component1140. In addition, the sliding movement pushes portions of the materialforming first polymer layer 1810 and second polymer layer 1820 downwardand further into depression 1780. Moreover, the material forming firstpolymer layer 1810 and second polymer layer 1820 compacts or otherwisecollects in the area between first seam-forming surfaces 1740 and secondseam forming surface 1770. Given that first seam-forming surface 1740and second seam-forming surface 1770 are angled relative to each other,the compacted polymer material forms a generally triangular or taperedstructure, which results in forefoot component flange 1146. In additionto forming forefoot component flange 1146, first polymer layer 1810 andsecond polymer layer 1820 are (a) shaped to form forefoot componentfluid-filled chambers 1145 and (b) compressed and joined to form webarea 1147.

At the stage of the process depicted in FIG. 11, a void volume 1790,which is located between compression surface 1750 and depression 1780within mold 1700, effectively has the shape of forefoot component 1140prior to inflation or pressurization. Moreover, a peripheral portion ofthe void includes an area that forms forefoot component flange 1146between first seam-forming surface 1740 and second seam-forming surface1770. The non-parallel configuration between first seam-forming surface1740 and second seam-forming surface 1770 results in a tapered spacewhere the polymer material collects to form forefoot component flange1146. A distance across the space between first seam-forming surface1740 and second seam-forming surface 1770 is greater adjacent to aportion of the void volume 1790 that forms fluid-filled components 1145than in the area where first seam-forming surface 1740 and secondseam-forming surface 1770 meet, which is spaced from the portion of thevoid that forms forefoot component fluid-filled chambers 1145. Althoughthe configuration of the tapered space between first seam-formingsurface 1740 and second seam-forming surface 1770 may vary, an angleformed between first seam-forming surface 1740 and second seam-formingsurface 1770 may be in a range of between twenty degrees and forty-fivedegrees.

As described above, the material forming first polymer layer 1810 andsecond polymer layer 1820 compacts or otherwise collects in the areabetween first seam-forming surface 1740 and second seam-forming surface1770. This compaction effectively thickens one or both of first polymerlayer 1810 and second polymer layer 1820. That is, whereas first polymerlayer 1810 and second polymer layer 1820 have a first thickness at thestage depicted in FIG. 11, one or both of first polymer layer 1810 andsecond polymer layer 1820 within flange 1146 may have a second, greaterthickness at the stage depicted in FIG. 11. The compaction that occursas pinch surface 1730 contacts and slides against a portion of secondseam-forming surface 1770 increases the thickness of the polymermaterial forming one or both of first polymer layer 1810 and secondpolymer layer 1820.

When forming forefoot component 1140 is complete, mold 1700 is openedand forefoot structure 1131 is removed and permitted to cool. A fluidthen may be injected into forefoot component 1140 to pressurize forefootcomponent fluid-filled chambers 1145, thereby completing the manufactureof forefoot sole structure 1131. As a final step in the process,forefoot sole structure 1131 may be incorporated into a sole structureof an article of footwear 100.

FIG. 10 and FIG. 11 illustrate an embodiment having relatively smalloverlap of forefoot outsole 1160 on forefoot component edges 1143 offorefoot component fluid-filled chambers 1145. FIG. 10 and FIG. 11 alsoillustrate an embodiment in which forefoot component edges 1143 offluid-filled chambers 1145 of forefoot component 1140 form a forefootsole structure 1131 having a continuous, smooth shape from forefootcomponent upper surface 1141 to forefoot component lower surface 1142.

FIG. 12 and FIG. 13 illustrate a mold for a heel component wherein heeloutsole 1170 is placed in a mold portion in an area that is not formedto accommodate the outsole. Then, the heel component 1150 is co-moldedwith and encompasses heel outsole 1170. This technique yields a heelsole structure 1132 having heel component edges 1153 flush with heeloutsole edges 1173.

Although a variety of manufacturing processes may be utilized, heel solestructure 1132 may be formed through a process that is generally similarto the process discussed above for forefoot component 1140 and forefootsole structure 1131. Mold 1190 that may be utilized in the manufacturingprocess is depicted as including a first mold portion 1191 and a secondmold portion 1192. Mold 1190 is utilized to form heel component 1150from additional elements of first polymer layer 1181 and second polymerlayer 1182, which are the polymer layers forming, respectively, heelcomponent upper surface 1151 and heel component lower surface 1152. Moreparticularly, mold 1190 facilitates the manufacturing process by (a)shaping first polymer layer 1181 and second polymer layer 1182 in areascorresponding with heel component fluid-filled chamber 1155 and heelcomponent flange 1156 and (b) joining first polymer layer 1181 andsecond polymer layer 1182 in areas corresponding with heel componentflange 1156 and heel component web area 1157. In addition, mold 1190facilitates the bonding of heel outsole 1170 to heel component 1150.

Each of first polymer layer 1181 and second polymer layer 1182 isinitially located between each of first mold portion 1191 and secondmold portion 1192, as depicted in FIG. 12. In addition, one or moreelements that form outsole 1170 are also located relative to mold 1190.Once first polymer layer 1181 and second polymer layer 1182 are properlypositioned and the elements of outsole 1170 are located within voidvolume 1198 in second mold portion 1192, first mold portion 1191 andsecond mold portion 1192 translate or otherwise move toward each otherand begin to close upon first polymer layer 1181 and second polymerlayer 1182, as depicted in FIG. 13. As discussed above, air may bepartially evacuated from the areas between (a) first mold portion 1191and first polymer layer 1181 and (b) second mold portion 1192 and secondpolymer layer 1182. Additionally, fluid may be injected into the areabetween first polymer layer 1181 and second polymer layer 1182. Fluidmay be selected from the group consisting of air, liquid, gel, andblends thereof. Using one or both of these techniques, first polymerlayer 1181 and second polymer layer 1182 are induced to engage thesurfaces of mold 1190. Additionally, first polymer layer 1181 and secondpolymer layer 1182 also lay against heel outsole 1170. In effect,therefore, first polymer layer 1181 and second polymer layer 1182 areshaped against surfaces of mold 1190 and outsole 1170, as shown in FIG.13.

As first mold portion 1191 and second mold portion 1192 continue to movetoward each other, first polymer layer 1181 and second polymer layer1182 are compressed between first mold portion 1191 and second moldportion 1192, as depicted in FIG. 14. More particularly, first polymerlayer 1181 and second polymer layer 1182 are compressed to form heelcomponent flange 1156 and heel component web area 1157. Polymer layer1182 also bonds with outsole 1170.

When the manufacture of heel sole structure 1132 is complete, mold 1190is opened and heel sole structure 1132 is removed and permitted to cool,as depicted in FIG. 15. A fluid then may be injected into heel component1150 to pressurize heel component fluid-filled chambers 1155, therebycompleting the manufacture of heel sole structure 1132. As a final stepin the process, heel sole structure 1132 may be incorporated into solestructure 1130 of article of footwear 100.

As first polymer layer 1181 and second polymer layer 1182 are drawn intomold 1190, particularly the larger volumes in second mold portion 1191,first polymer layer 1181 and second polymer layer 1182 stretch toconform to the contours of mold 1190. When first polymer layer 1181 andsecond polymer layer 1182 stretch, they also thin or otherwise decreasein thickness. Accordingly, the initial thicknesses of first polymerlayer 1181 and second polymer layer 1182 may be greater than theresulting thicknesses after the manufacturing process.

FIG. 17, FIG. 18, and FIG. 19 illustrate other embodiments of heel solestructures. FIG. 17 illustrates heel sole structure 2732 including heeloutsole portions 2770. In embodiments illustrated in FIG. 17, heeloutsole portions 2770 have a first thickness at the ground-engagingarea, such as the location for traction lugs, and a second, lesserthickness on at least part of one or both vertical surfaces of heelcomponent fluid-filled chamber 2755. The thickness may be changed in agradual way, such as by a linear taper, or may be stepwise. Heel outsoleportions 2770 are thinner on the outside vertical surfaces of heelcomponent fluid-filled chamber 2755 than they are at the ground-engagingarea. In this way, the elastic response of heel sole structure 2732 maybe tuned.

FIG. 18 illustrates heel sole structure 2832 having heel outsoleportions 2870, which are thinner on both vertical surfaces of heelcomponent fluid-filled chambers 2855 than they are at theground-engaging area. In other embodiments, only the inside verticalsurfaces of heel outsole portions 2770 or 2870 may be thinned on thevertical surfaces of heel component fluid-filled chambers 2755 or 2855,respectively.

In some embodiments, any combination of such configurations may be used,thus providing additional opportunities to tune the elastic response ofthe heel sole structure.

FIG. 19 illustrates another embodiment of a heel sole structure. Heelsole structure 1932 includes heel outsole portions 1970. Heel outsoleportions 1970 extend up the interior vertical surfaces of heel componentfluid-filled chambers 1955 to heel component web area 1957. The heeloutsole portions also include a flange that extends across a portion ofheel component web area 1957. This flange provides an additional featurethat can be varied to tune the elastic response of the heel component.Heel outsole portions 1970 extend a distance up the exterior verticalsurfaces of heel component fluid-filled chambers 1955. This distancealso may be varied to adjust the elastic response of the heel outsoleportions.

Any of these and other suitable manufacturing techniques may be used toform forefoot structures and heel structures. In particular, amanufacturing technique described herein for a forefoot structure may beused to form a heel structure, and a technique described herein for aheel structure may be used to form a forefoot structure. Separate partsmay be bonded to a corresponding component by adhesion or by partialmelting. In some embodiments, an outsole may be thermally bonded to acorresponding component during the manufacturing process to form a solestructure. For example, when each of a second polymer layer and thecorresponding outsole are formed from similar or compatible polymermaterials, or when the outsole is at least partially formed from thepolymer material of a fluid-filled chamber, heating of the polymerlayer/fluid-filled chamber and the outsole may induce thermal bondingbetween the components. Similarly, ground-engaging lugs may be formedintegrally with an outsole, or may be bonded thereto using any suitabletechnique, such as adhering or partial melting. In some embodiments, itmay be convenient to bond parts with heat-activated adhesive.

In some embodiments, a polymer layer of a fluid-filled chamber to whichthe ground-engaging portions of an outsole may be attached by co-moldingor may instead be co-extruded with the outsole ground-engaging portions.In this manner, the manufacture of the components may be simplified,including in particular making molding easier. If lugs are to be added,the lugs may be placed in the mold for co-molding with the other partsof the outsole, as described above.

In some embodiments, the fluid-filled chamber layer and the outsoleportions may be compatible compositions that may be co-extruded asadjacent layers that may form a mutual bond upon co-extrusion. In someembodiments, a tie layer may be required to adhere an outsole portion toa fluid-filled chamber polymer layer. In some embodiments, lugs formingpart of the ground-engaging outsole may be placed in the mold andco-molded with the rest of the layers.

With the guidance provided herein, the user will be able to identify asuitable method without undue experimentation.

The joints between lugs and outsoles and between outsoles and componentsmay be made aesthetically pleasing in embodiments of the disclosure inwhich the joint can be seen by the user, for example when the piecesthat form the sole structure are transparent or translucent. In someembodiments, an adhesive that softens in response to heat, such as theheat of molding, also may be suitable.

In some embodiments, an outsole piece that may be positively sprung maybe pressed into a mold. A fluid-filled chamber may be overmolded ontothe outsole piece. Although the thermoforming molds may have undercuts,the outsole pieces typically do not. In such embodiments, a non-undercutoutsole piece may create distortion in the outsole element. Inparticular, the outsole piece may pull away from the mold side wall.However, the fluid-filled chamber then is over-molded onto the outsolepiece. The overmolding pushes the outsole back into position whenpressure is introduced into the fluid-filled chamber in the mold, andthus pushes the outsole into shape. This technique is fully illustratedin [application incorporated by reference].

Method for Manufacturing an Article of Footwear

An article of footwear having an upper and a sole structure may bemanufactured by securing at least part of the upper to at least part ofthe sole structure. In some embodiments, the sole structure includes afluid-filled chamber that includes an edge, an upper surface, and alower surface. The sole structure also includes an outsole. The outsoleis co-molded to at least a part of the lower surface of the fluid-filledchamber and to at least a part of the edge of the fluid-filled chamber.The outsole is co-extensive with at least part of the lower surface ofthe chamber and with at least part of the edge of the chamber. Theoutsole and the fluid-filled chamber may be bonded by adhesive or bypartially melting at least one of the surfaces to be bonded.

Method for Minimizing Gas Inclusions

In some embodiments, particularly when adhesive is used to bond anoutsole to a component to form a sole structure, a feature that someusers may find aesthetically objectionable may form. As shown in FIG. 4,feature 900 is an example of an inclusion that is a small gas bubblebetween forefoot outsole 1160 and forefoot component fluid-filledchamber lower surface 1142, both of which may have smooth surfaces. Suchinclusions may not be visible in all circumstances. However, theinclusions may weaken the bond between the component and the outsole,especially if the inclusions are concentrated or prevalent in an area.

In some embodiments, the bond between parts may be made moreaesthetically pleasing and stronger by providing a texture on at leastone of the component lower surface and the outsole inside lower surface.In some embodiments, the textured surface may have lands and grooves, orhigh areas (e.g., projections) and low areas (e.g., recesses). In someembodiments, gas escape openings in an outsole may allow trapped gas toescape.

In some embodiments, the thickness of the adhesive is less than thedepth of the grooves or low areas of the texture. An excess of adhesivemay weaken the bond because it may preclude sufficient contact betweenthe surfaces, i.e., between the high areas of the textured surface andthe other surface, by filling the volumes between the low areas of thetexture. Filling the low area of the texture may force the land, or higharea of the texture, away from the other surface, thus precluding goodbonding.

The texture need not be regular or patterned, but, as described above,should ensure that the high areas are of consistent height andsufficiently prevalent so as to ensure adequate contact between theoutsole and the component lower surface. In some embodiments, thetexture is a regular, repeating, patterned texture, such as straightgroves, intersecting grooves, circles, triangles, or any other shape. Insome embodiments, other aesthetically pleasing texture, such as words,letters, numbers, logotypes, or slogans may be suitable textures.

Although a textured bonding surface may trap a quantity of gas duringbonding, the texture may serve to minimize any reduction in strength andmay contribute to a pleasing aesthetic. In some embodiments, the texturemay serve to ensure that any large inclusions are precluded and brokeninto smaller inclusions distributed over the surface. Also, a regularpattern, such as that illustrated in FIG. 16, may be more aestheticallypleasing because low points may include a gas bubble or the appearanceof a gas bubble, thus presenting a regular appearance. Further, such apattern may yield a high-strength bond, as the adhesive is able to forma good bond between the high points and the other surface. A texturealso may form excellent bonds on areas adjacent high points, as theadhesive may spread between the surfaces to form a strong bond.

FIG. 16 illustrates a top view of forefoot outsole 160 having forefootoutsole compartments 165 and forefoot outsole inner edges 164. Forefootoutsole inside lower surface 166 is textured with a regular pattern ofnon-parallel grooves that form a square or diamond pattern on theforefoot outsole inside lower surface 166. In some embodiments, thelines indicate raised areas, and the area between the lines is a lowarea. In some embodiments, the lines indicate grooves cut into thesurface. With the guidance provided herein, the user can identify asuitable texture for either surface.

FIG. 20, FIG. 21, FIG. 22, and FIG. 23 illustrate additional embodimentsrelated to minimizing air inclusions between outsole portions andfluid-filled chamber lower surfaces. FIG. 20 is a bottom view of anarticle of footwear in accordance with some embodiments of thedisclosure. FIG. 21 illustrates an embodiment of a heel outsole. FIG. 22illustrates an interior structure for enhancing gas movement to a gasescape opening. FIG. 23 illustrates another embodiment of a heeloutsole. These and other structures may be used to minimize airinclusions.

FIG. 20 illustrates sole structure 2130, which is secured to the lowerend of an upper, such as upper 120 (FIG. 1). Sole structure 2130 islocated under the foot and supports the foot. The primary elements ofsole structure 2130 are a forefoot sole structure 2131 including aforefoot component 2140 and forefoot outsole portions 2060, and a heelsole structure including a heel component 2150 and a heel outsole 2070.In some embodiments, each of forefoot component 2140 and heel component2150 may be directly secured to a lower area of the upper. Forefootcomponent 2140 and heel component 2150 are formed from a polymermaterial that encloses a fluid, which may be a gas, liquid, or gel.During walking and running, for example, forefoot component 2140 andheel component 2150 may compress between the foot and the ground,thereby attenuating ground reaction forces. That is, forefoot component2140 and heel component 2150 are inflated and generally pressurized withthe fluid to cushion the foot.

In some configurations, sole structure 2130 may include a foam layer,for example, that extends between upper 120 and one or both of forefootcomponent 2140 and heel component 2150, or a foam element may be locatedwithin indentations in the lower areas of forefoot component 2140 andheel component 2150. In other configurations, forefoot sole structure2131 may incorporate plates, moderators, lasting elements, or motioncontrol members that further attenuate forces, enhance stability, orinfluence the motions of the foot. Heel sole structure 2132 also mayinclude such members to further attenuate forces, enhance stability, orinfluence the motions of the foot.

In addition to providing a wear surface in article of footwear 100,forefoot outsole 2060 and heel outsole 2070 may enhance variousproperties and characteristics of sole structure 2130. Properties andcharacteristics of the outsoles, such as the thickness, flexibility, theproperties and characteristics of the material used to make the outsole,and stretch, may be varied or selected to modify or otherwise tune thecushioning response, compressibility, flexibility, and other propertiesand characteristics of sole structure 2130. Reinforcement of the outsole(for example, inclusion of structural elements, such as ribs),apertures, the height of the overlap, the number and location of theedges that overlap, or other features of an outsole all may be used totune the responses of the sole structure. An outsole also mayincorporate tread elements, such as protrusions, ridges, orground-engaging lugs or sections, that impart traction. In someembodiments, an outsole may be replaced by a plate or other structuralelement. A plate may have features that assist with securing an outsoleor other element to heel component 2150.

In particular, overlap of a portion of an outsole away from theground-engaging portion and up the edge of a forefoot component or aheel component, such as described above and illustrated at least in FIG.17, FIG. 18, and FIG. 19, may be used to tune the elastic response andcushioning response of the resultant sole structure. With the guidanceprovided herein, these and other properties and characteristics of theoutsole may be considered by the user in combination with the propertiesand characteristics of the fluid-filled components of the components toadjust the responses of a sole structure.

Sole structure 2130 may be translucent or transparent, and may becolored or patterned for aesthetic appeal.

Forefoot outsole 2060 is secured to lower areas of forefoot component2140. In some embodiments, forefoot sole structure 2131 may extend intoa midfoot region. The forefoot outsole 2060 also may be secured to lowerareas of forefoot component 2140 in a midfoot region. Heel outsole 2070is secured to lower areas of heel component 2150. Both heel component2150 and heel outsole 2070 may extend into a midfoot region. Forefootoutsole 2060 and heel outsole 2070 may be formed from a wear-resistantmaterial. The wear-resistant material may be transparent or translucentto provide a visually appealing effect. The wear-resistant material maybe textured on the ground-engaging portions to impart traction. In someembodiments, the wear-resistant material may have ground-engaging lugsor portions 2135, as illustrated in FIG. 20.

FIG. 20 also illustrates gas escape openings 2069 in forefoot outsoleportions 2060 and gas escape openings 2079 in heel outsole portions2070. These gas escape openings allow air or other gases trapped betweena component and the corresponding outsole during assembly to escape. Theinside surface of an outsole portion may be shaped in a manner that mayaccumulate trapped gas and direct the entrapped gas to a gas escapeopening. For example, small passages, such as a small tunnel or removedarea, may be formed on the inside surface of the outsole portion.

FIG. 21 and FIG. 22 illustrate an embodiment of a heel outsole. FIG. 21illustrates an embodiment of such gas escaping openings 2179. Theseopenings 2179 may be located on the bottom surface of heel outsole 2170or forefoot outsole 2060. Some gas escape openings may be close to theground-engaging surface, such as FIG. 21 through FIG. 25, whereas othersmay be located between ground-engaging portions, such as gas escapeopening 2189. FIG. 21 also illustrates ground-engaging lugs 2135 and gasescape openings 2179.

FIG. 22 illustrates embodiments of gas escape passages and volumes onthe inside surface of heel outsole 2170. FIG. 22 illustrates gasaccumulation areas 2178 present in association with gas escape openings2179. The gas accumulation areas 2178 and passages 2181 serve to reduceinclusions between the heel component and heel outsole 2170. Gasaccumulation passages 2181 may connect gas escape openings 2189 to gasaccumulation area 2178. As an illustration, each member of the gasaccumulation system need not be connected to every other member. Forexample, gas accumulation area 2182 is not continuous with or connectedto adjacent gas escape passage 2179.

FIG. 23 illustrates an embodiment wherein the gas accumulation passages2278 are formed as a regular pattern on the inside surface of outsole2270. Gas accumulation passages 2278 provide texture in outsole insidelower surface 2288, as illustrated in FIG. 23, in the enlarged view FIG.24, and in FIG. 25. Gas accumulation passage 2278 is formed by highareas 2290 and low areas 2291. Low areas 2291 have a depth in outsoleinside lower surface 2288. Gas escape openings 2279 are present inoutsole 2270. Each of gas escape openings 2279 is in communication witha gas accumulation passage 2278. In some embodiments, each of thepassages 2278 is associated with other passages, so gas accumulated inthe pattern of gas accumulation passages 2278 may escape through a gasescape opening 2279. Thus, imperfections from captured gas bubbles maybe minimizes for a clear, clean, unblemished appearance. In someembodiments, gas escape passages 2279 not located on a ground-engagingsurface need not be associated with gas accumulation passages 2278.

FIG. 26 illustrates an embodiment wherein the thickness of the adhesiveis less than the depth of the low area of the texture on the insidelower surface of the outsole. FIG. 26 illustrates a cross-section of aportion of outsole 2270 adhered by adhesive 2299 to component 2295.Adhesive 2299 has a thickness. As can be seen in FIG. 26, adhesive 2299completely fills the region between outsole inside lower surface 2288and component 2295, and extends into gas accumulation passage 2278,which has high areas 2290 and low areas 2291. However, adhesive 2299 hasa thickness that is less than the low areas 2291 of gas accumulationpassages 2278.

Although FIG. 21, FIG. 22, and FIG. 23 depict only heel-related objects,the principles expressed in each also may be applied to a forefootsection to produce a forefoot section similar to the heel-relateddisclosure herein. The skilled practitioner can readily determine how toextend the principles used to form a heel outsole to form a forefootoutsole.

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. For example, rather than a square or diamond-shapedtexture on the interior of an outsole, another pattern, such astriangles, pentagons, or circles may be used. Accordingly, the inventionis not to be restricted except in light of the attached claims and theirequivalents. Also, various modifications and changes may be made withinthe scope of the attached claims.

What is claimed is:
 1. A method of manufacturing a sole structure for anarticle of footwear, the method comprising: forming a fluid-filledchamber having a plurality of fluid-filled segments each having an uppersurface, a lower surface, and an edge extending between the uppersurface and the lower surface; forming an outsole having a plurality ofcompartments that each correspond to a fluid-filled segment of theplurality of fluid-filled segments and each include a ground-engagingsurface and a segment-engaging surface formed on an opposite side of theoutsole than the ground-engaging surface, at least one of thesegment-engaging surfaces including a series of lands and grooves; andbonding the lands of the at least one of the segment-engaging surfacesto the lower surface of a respective one of the plurality offluid-filled segments to space the grooves apart from the lower surfaceof the respective one of the plurality of fluid-filled segments, whereinforming the fluid-filled chamber having a plurality of fluid-filledsegments includes forming a first one of the plurality of fluid-filledsegments to include a first portion extending along one of a medial sideof the sole structure and a lateral side of the sole structure, a secondportion extending from the first portion toward the other of the medialside and the lateral side and having a distal end that terminatesbetween the lateral side and the medial side, and a third portionextending from the first portion toward the other of the medial side andthe lateral side and having a distal end that terminates between thelateral side and the medial side.
 2. The method of claim 1, furthercomprising extending a portion of the outsole onto the edges of theplurality of fluid-filled segments.
 3. The method of claim 2, furthercomprising bonding the lands of the at least one of the segment-engagingsurfaces to the edge of the respective one of the plurality offluid-filled segments.
 4. The method of claim 1, wherein forming thefluid-filled chamber having a plurality of fluid-filled segmentsincludes forming a second one of the plurality of fluid-filled segmentsto include a fourth portion extending along the other of the medial sideand the lateral side, a fifth portion extending from the fourth portiontoward the one of the medial side and the lateral side and having adistal end that terminates between the lateral side and the medial side,and a sixth portion extending from the fourth portion toward the one ofthe medial side and the lateral side and having a distal end thatterminates between the lateral side and the medial side.
 5. The methodof claim 4, further comprising aligning the second portion with thefifth portion across the sole structure in a direction extending betweenthe medial side and the lateral side and aligning the third portion withthe sixth portion across the sole structure in the direction extendingbetween the medial side and the lateral side.
 6. The method of claim 1,wherein forming the outsole to include at least one segment-engagingsurface having a series of lands and grooves includes providing theseries of lands and grooves having a regularly repeating pattern.
 7. Themethod of claim 1, wherein forming the outsole to include at least onesegment-engaging surface having a series of lands and grooves includesproviding the series of lands having a square shape or a diamond shape.8. The method of claim 1, wherein forming the fluid-filled chamberhaving a plurality of fluid-filled segments includes forming at leastone of the fluid-filled segments into a C-shape.
 9. The method of claim1, wherein bonding the lands of the at least one of the segment-engagingsurfaces to the lower surface of a respective one of the plurality offluid-filled segments includes at least one of using an adhesive andfusing a material of the corresponding fluid-filled segment with amaterial of the outsole.
 10. A method of manufacturing a sole structurefor an article of footwear, the method comprising: forming afluid-filled chamber having a plurality of fluid-filled segments eachhaving an upper surface, a lower surface, and an edge extending betweenthe upper surface and the lower surface; forming an outsole having aplurality of compartments that each correspond to a fluid-filled segmentof the plurality of fluid-filled segments and each include aground-engaging surface and a segment-engaging surface formed on anopposite side of the outsole than the ground-engaging surface, at leastone of the segment-engaging surfaces including a series of projectionsdefining a series of recesses; and bonding the projections of the atleast one of the segment-engaging surfaces to the lower surface of arespective one of the plurality of fluid-filled segments to space therecesses apart from the lower surface of the respective one of theplurality of fluid-filled segments, wherein forming the fluid-filledchamber having a plurality of fluid-filled segments includes forming afirst one of the plurality of fluid-filled segments to include a firstportion extending along one of a medial side of the sole structure and alateral side of the sole structure, a second portion extending from thefirst portion toward the other of the medial side and the lateral sideand having a distal end that terminates between the lateral side and themedial side, and a third portion extending from the first portion towardthe other of the medial side and the lateral side and having a distalend that terminates between the lateral side and the medial side. 11.The method of claim 10, further comprising extending a portion of theoutsole onto the edges of the plurality of fluid-filled segments. 12.The method of claim 11, further comprising bonding the projections ofthe at least one of the segment-engaging surfaces to the edge of therespective one of the plurality of fluid-filled segments.
 13. The methodof claim 10, wherein forming the fluid-filled chamber having a pluralityof fluid-filled segments includes forming a second one of the pluralityof fluid-filled segments to include a fourth portion extending along theother of the medial side and the lateral side, a fifth portion extendingfrom the fourth portion toward the one of the medial side and thelateral side and having a distal end that terminates between the lateralside and the medial side, and a sixth portion extending from the fourthportion toward the one of the medial side and the lateral side andhaving a distal end that terminates between the lateral side and themedial side.
 14. The method of claim 13, further comprising aligning thesecond portion with the fifth portion across the sole structure in adirection extending between the medial side and the lateral side andaligning the third portion with the sixth portion across the solestructure in the direction extending between the medial side and thelateral side.
 15. The method of claim 10, wherein forming the outsole toinclude at least one segment-engaging surface having a series ofprojections and recesses includes providing the series of projectionsand recesses having a regularly repeating pattern.
 16. The method ofclaim 10, wherein forming the outsole to include at least onesegment-engaging surface having a series of projections and recessesincludes providing the series of projections having a square shape or adiamond shape.
 17. The method of claim 10, wherein forming thefluid-filled chamber having a plurality of fluid-filled segmentsincludes forming at least one of the fluid-filled segments into aC-shape.
 18. The method of claim 10, wherein bonding the projections ofthe at least one of the segment-engaging surfaces to the lower surfaceof a respective one of the plurality of fluid-filled segments includesat least one of using an adhesive and fusing a material of thecorresponding fluid-filled segment with a material of the outsole.